Experimental and numerical investigation of fiber metal laminate forming behavior using a variable blank holder force
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PRODUCTION PROCESS
Experimental and numerical investigation of fiber metal laminate forming behavior using a variable blank holder force Hamza Blala1 · Lihui Lang1 · Shahrukh Khan1 · Sergei Alexandrov1 Received: 30 April 2020 / Accepted: 24 July 2020 © German Academic Society for Production Engineering (WGP) 2020
Abstract Structural integrity, fuel efficiency, and reduced emission of greenhouse gases are the topmost priorities of the modern-day aerospace and automobile industries. Fiber-metal laminates (FMLs) can reduce most of these concerns by reducing a significant amount of weight without compromising structural reliability. Although this material was invented a few decades ago, large scale production, especially the forming process of small and complex-shaped products, has not matured yet. The necessity of manual processing makes it more cost-intensive and time-consuming. The forming difficulty comes with the limited elongation of the fiber layers compared to the metallic layers. As a result, the conventional approaches to form FMLs parts are not very suitable. In this paper, an investigation has been conducted to improve the drawability of FMLs sheets in deep drawing of cylindrical cups, made of semi-cured Glare material. A variable blank holder force (VBHF) method was proposed, which means the variation of the friction force of the holder and the laminate on contact surfaces, as a function of the position of outer flange edge. Fracture and wrinkling limits have been determined, and a BHF control trajectory has been presented to improve the forming quality, increase the drawing depth, and eliminate defects. Both experimental and numerical results from the VBHF were compared with constant BHF results. It is evident that the proposed VBHF scheme helps to improve the drawing quality compared to the conventional constant BHF. As a result, this method can enhance the production rate as well. Keywords Laminate · Composite · Deep drawing · Blank holder force (BHF) · Wrinkling · Thinning
1 Introduction Reduction of the structural weight results in better fuel efficiency and reduced emission of C O2 and maintenance costs. However, reducing weight may compromise the structural integrity of the vehicle. That means new materials need to have certain qualities such as lower weight, durability, and higher damage-tolerant to fulfil the demand of modern-day * Hamza Blala [email protected] Lihui Lang [email protected] Shahrukh Khan [email protected] Sergei Alexandrov [email protected] 1
School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing 100191, China
industries [1]. Composite materials have the potential to improve structural integrity and cost-effectiveness. However, they still have restrictions that limit their extensive use, especially for mass production of small complex shapes [2, 3]. FMLs, that originated from metal bonding are lightweight hybrid composite materials. These FMLs were developed in the aerospace industry to avoid inter ri
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